Pro Weld Performance Parts

Complete 4.6L & 5.4L Engines

Home
Bargin Pitt
What's New!
Socket Head Bolts, Nuts, Washers & Spacers
The Cobra Connection
Engine Blocks
Custom Wiring Harnesses & Electrical Supplies
Fuel Injection
Specialty Tools and Taps
Fittings
Insulation
Our Policies
Our Location
About Us
Complete 4.6L & 5.4L Engines
03-04 Cobra Assembly Manual
Inter-Cooler Coolant System
Cobra Specific Parts Page
ProWeld Projects Page
4.6L, 5.4L & 5.0L Parts and Accessories
Engine Building Service
Super Coolers
ProWeld 2, 3 & 4 Valve Heads
Ford 4.6L Dry Sump Kit
Coatings
Socket Head Bolt Kit Page
ARP Engine & Automotive Fasteners
4ValveEngines/LargeGroupPictureAlbum127421.jpg
5.4L GT500 DOHC, Oliver Rods, Diamond,8-Stack EFI

4ValveEngines/LargeGroupPictureAlbum127421.jpg
4.6L DOHC Single Turbo Engine

4ValveEngines/LargeGroupPictureAlbum127421.jpg
03-04 Based Engine for American Iron Series

4ValveEngines/LargeGroupPictureAlbum127421.jpg
4.6L DOHC 03-04 Cobra Engine

4ValveEngines/LargeGroupPictureAlbum127421.jpg
4.6L DOHC 03-04 Cobra Engine

2ValveEnginePictures064.JPG
This is a clean example of a 99-01 2-Valve Engine

ProWeld has always offered complete Engines, I guess were just making it official...

We build everything from complete factory offerings to all out race Engines, with most somewhere in between the two extremes. We have supplied parts or complete Engines to those building Cobra Replicas, Factory Five Kit Cars, Original Cobra Restorations, and some that transplanted the Cobra 03-04 Engine into Ford GT's. The Ford Modular Engine is just now starting to see activity in the Hot Rod, Kit Car markets, and other Project Vehicles. The range of 2-Valve, 3-Valve and 4-Valve projects is heating up and we can supply any engine you want or demand, from 300 to 1500 horsepower!

We can provide the complete Engine or just the Short Block, it's your choice. We specialize in doing Complete Engines, where not only is the Engine built to your needs, but the Fuel System, Ignition System, Power Adder, Wiring and Plumbing is also installed, making for a complete ready to install package. We are a dealer for Telorvek Wiring Harnesses, and use them almost exclusively in all our modular Engines. They make the best wiring kits, bar none. The number one complaint or trouble area on these Engines is in the wiring. There are just too many connections of vital parts to be messing around with old used harnesses, let alone one trying to modify one harness to do the job for a different Engine combination.


Do yourself a favor, if you don't listen to anything I have to say on this page, please listen up to this advice, and start your new project with a
New Wiring Harness. It saves time, will save you money, will work, and most important, it will keep working. Our wiring is easy for a Ford technician to follow, do diagnostics and make repairs on. You will be far ahead if you follow along on this…..Trust me.

2-Valve Engines

 

    For a long time, the 2-Valve market was pretty stagnant...But there has been a real interest in 2-Valve Engines since the release of the new Trick Flow Heads, and the improvement in both carbureted and aftermarket fuel injection systems. This re-designed Head allows for much better breathing, in-fact the stock un-ported heads flow much better than any high dollar, custom ported 2-Valve Head. This means more HP for much less money, and better efficiency and improved power output. The small size of the 2-Valve Head makes if perfect for smaller Engine compartments, and lower hood lines. You can choose from cast iron or aluminum blocks, and have a very powerful small block Engine, one that fits in many vehicles without having to modify or replace the firewalls. This makes the 2-Valve, a great choice for many Hot Rod or Kit Car Vehicles.

     The 2-Valve Modular Engine offers both Performance, Weight and Size advantages that other Modular engines don't, plus it is the most affordable engine to build and maintain. Think about it for a moment? You have half the Valves($10-22), Springs($5-12), Retainers($3-15), Hydraulic Tensioners($35-45), Chains($35-65), Hydraulic Lifters($12-25), Rockers($10-40), Cam Journals, Seals($2-4), Valve Seats($25-45) & Guides($12-35) compared to a 4-Valve Engine! I assigned a dollar amount to the items listed, that range from stock to race in price, take each example and multiple them each by 16 and you'll see the difference. The Savings are very real!! Plus add in the repairs cost savings: cheaper to rebuild a 2-Valve Head, less Porting work, less cam journals to repair, less weight and half as many items to fail.

     The 2-Valve Head was limited at one time by flow. You can only get so much air thru any head, and at one time, the air flow was very poor compared to the 4-Valve Head. This limited power, so the 2-Valve Head  never got the respect it deserved nor was considered a real power Engine. Now things have definitely changed, the newer designs of the Trick Flow Heads have very good Flow Numbers, meaning they now can make as much power as any other Modular Engine Head. So if you like that look, have limited space under the hood, or just need to trim some expense from your project, the 2-Valve Modular Engine is now a very viable option.

BuiltEngines/041210Mod025.JPG
ne of the few 3-Valve Engine we built.

3-Valve Engines


   3-Valve Engines are newer in the line of modular power plants from Ford. They too offer smaller engine packages which work well in Hot Rods and Kit Car re-powers. The 3-Valve Heads flow some very impressive numbers right out of the box and the Variable Cam Timing makes great torque and power. You can have a factory Ford like Engine, or customize one for your specific needs, either way they fit the bill for many applications. The aftermarket has responded well to this engine, and there are many custom pieces available for it.

    Ford built a ton of these 3-Valve Engines, in everything from the F-Series Trucks to Mustangs. With a model run from 2004-2010, the engine had its legs chopped from beneath it by the all new 5.0L Coyote. I don't think the 3-Valve will go down as anything but the worst of the Modular Engine design. Head issues with over-heating, spark plug retention and breakage, plus many problems associated with short engine life when pushed for more performance, has left this Engine with no further aftermarket support. Too Bad, I think under the right circumstances this would be a nice little Engine, with great potential. But Ford lost interest very early on, and the aftermarket cut product development as soon as the 5.0L was released.  Still, there were a lot of 3-Valve Engines produced, and that means there will be a ton of these Engines available for Hot Rodders. 


DSC02920.JPG
01 4.6L DOHC Cobra Engine

4-Valve Engines

    The 4-Valve Modular Engine has to be one of the Greatest Engine designs Ford has ever come out with. The highly complex and efficient design work extremely well, and has amazing power for such a small displacement Engine. While not light weight, and certainly not considered a compact engine, the Ford 4-Valve has graced everything from Ford Trucks, SUV's, Sedan, and Sport models, all the way to the best and most expensive vehicle Ford has ever produced, the Ford GT. Voted one of the best top 10 Engine designs in history, the Ford 4-Valve Engine has a very special place in my heart.

It is the reason I got into this, and the reason I stay!

 

     To say we specialize in the 4-Valve Engine would be an understatement. I simply adore the thing. While every other US manufacturer continued to build Engines based on very early designs, Ford has always set itself apart by being very aggressive in new Engine technology, and not being afraid to bring it's designs to market. In the very beginnings, back in 1993 when they released the first 4-Valve Engines. Up and until that time, to get a V-8 DOHC 32-Valve Engine, you would have to shop the exotic car market, not Ford. Only Ferrari, Lamborghini, and a hand full of specialty makes made such Engines, and the price was astronomical. In fact, the first several years, Ford had what was to be known as the " TEKSID " Block. The very first 4-Valve Engine Blocks, These all aluminum TEKSID Blocks were made in Turin, Italy by TEKSID Aluminum Inc., the World's leader in Cast, Forged and Lost-Foam Aluminum Engine parts. TEKSID, provides the world's best automotive manufacturers with the highest quality aluminum pieces in the world! They provide Ferrari, Lamborghini, Fiat, Porsche, Opal, Ford, Maseratti, Audi and many other automotive manufacturers with the highest quality aluminum parts available.

     Yes, I consider both the old and new 4-valve Engines to be World Class Engines. We specialize in the 03-04 Cobra Engine, which many refer to as the " Terminator" Engine. This is the most popular platform to work from as it is probably also the best known performance platform available. Generally, I consider the 03-04 Engine to be good for up to 500-550 horsepower, after that you need a bigger blower and better internal parts. But, with the 4-Valve Engine as a whole, there appears to be no limits on its potential! Today we see 2600-2800HP and with the new 5.0L engine coming along, there appears to be no limits except rationality and money. The 4-Valve Engine market is just getting started, and with so much attention today on both Superchargers and Turbochargers, the future looks quite good.

     You do not have to spend a fortune or need 2000HP, most application call for far less power, generally 500-750HP. This is very reasonable, attainable and reliable. There is no mistaking a 4-Valve Engine, with its huge, signature Valve Covers…many mistake it for a Dodge Hemi Engine. But truth be known, it is physically larger then a Hemi, and weighs about the same, even though it has much less displacement! As noted, power output is excellent. Reliability is very good, with many engines exceeding 200K miles between major service. Fuel economy is also one of the Engine's excellent properties, most combinations, in both automatic and manual equipped vehicles, constantly report low to mid 20's for their fuel mileage figures. Way better than the 5-9 MPG most Hot Rodders experience with larger displacement Engines producing this much power.

     While most think of the 99-01 Cobra or 03-04 Cobra, when thinking about the 4-Valve Modular Engine.  Truth be told, there are many versions of this amazing Engine to choose from.  The very first of the version was the Early Lincoln and Cobra's with the "B" Headed 4-Valve Engine's.  These Engines, known as Intech, started the ball rolling and have the same basic architecture as current configurations, only major difference is in Head and Intake design.  The Intake Manifold Runner Control (IMRC) is hard to label as old or dated, being that Ford re-used that very feature years later in the 3-Valve Engine.  But, it is this feature that most remember the early 4-Valve Engines for.  I can't say the lack of current popularity for this design was due to performance, as many racers currently still use these heads to compete at the highest levels.  I think it came down to choice, as in choice of manifolds available and lack of complexity of the system.  Personally I think the 96-98 Cobra manifold is one of, if not the best looking production manifolds on the market.  It can be beautiful when done right…and we have had a chance to do a few in the past.  But older Lincoln and Cobra Manifolds are getting hard to find.

   The next generation of the 4-Valve Engine came in the form of the 99-01 Cobra.  This gave us the newer generation "C" Headed 4-Valve 4.6L Engine.  Gone are the cables and butterfly valves operating the IMRC plates, and in its place came a cleaner design, with less complexity.  This was an interesting time, as Ford was preparing for the future, one that no one saw coming!  The new 99 Cobra was a hit, then we got the 2000 Cobra "R" ….5.4 Liters of naturally aspirated performance.  Turns out the "R" was just a design study for better things to come.  From that Ford learned and we got another new 4-Valve Head design, and in 03 they released the new 2003 Cobra, complete with Supercharger and all!  As it turns out, this was the tipping point for the Modular Engine, as up till this time, the aftermarket seemed very slow to embrace the Modular Platform.  But with such performance on tap, and more to come, the new parts started to arrive and along with the NMRA or National Mustang Racers Association, the rest is history.

    Now we have had the 05-06 Ford GT, The Ford Racing FR500 which brought us the 5.0L Cammer Engine in its many forms and raced in Daytona Prototype (DP), GT & GTII and many other classes of competition, to the Ford GT500 and its 5.4L & now 5.8L 4-Valve Engines.  I think its probably easy to say, that the effect the  Modular Engine program has had on Ford has been truly a blessing.  Some might even say it save the company!  Now the future is still full of 4-Valve Engine technology.  Call it the Coyote or the Road Runner, but the new 4-Valve Engine package Ford has currently released, is full of promise and holds a bright future for all Ford fans.  This Engine has taken everything learned over the past 20 years and combined it with the latest in electronics and combustion technology, to bring us full circle.  Now we have 4-Valve ,Variable Valve Timing Control, which allows almost endless scenarios of torque rich low end and high revving upper register, it would make a 60's racers head spin.  Never has technology played such a huge part in fuel, timing, cam and ignition control.  Down the line we can look forward to even more power and efficiency , with direct injection, turbo-charging and improved materials to come.  Engines are getting lighter, more durable, producing more power  across a wider RPM bandwidth, and all while continuing to get better fuel economy than ever before.  Ford is truly in a very good spot right now in the car industry.  I cannot wait to see what they come out with next !!


BreathersCobras/Cobra062010038.JPG
4.6L 03-04 Cobra Engine

BreathersCobras/Cobra062010038.JPG
4.6L DOHC 03-04 Cobra Engine

BreathersCobras/Cobra062010038.JPG
Blue 4.6L 03-04 Cobra Engine with Radiator & Hoses

BreathersCobras/Cobra062010038.JPG
Blue 4.6L 03-04 Cobra Engine

BreathersCobras/Cobra062010038.JPG
Test Stand W/4.6L 03-04 Cobra Engine

4-Valve  03-04 Cobra "Terminator" Engine

     In Both 2003 and 2004, Ford Built one of the very best Modular Engine of all time, the Ford 03-04 Cobra Engines. Best known as the "Terminator" or 03-04 Cobra Engine, it has a huge following. These Engine produced an amazing amount of power, and yet managed to get over 20 MPG of the highway! Sold only in the highest line of Ford Mustangs, known as the Cobra package, Ford sold just a little over 15,000 of these cars in the two year span….But that doesn't really tell the story. When these first started hitting the streets, all the known rules changed overnight. Everyone wanted one, but the high price tag prevented most from enjoying this Engine, and with that can the huge following. Websites were built around this car, as was many retail outlets, the draw was amazing, and it hasn't change a bit…These are the most sought after Engines there is, right up there with the Hemi's..except the Hemi's were placed in millions of cars, over several decades…remember, there were only 15,000 -/+ of these built! And in only 2-years!

     I think it's probably fair to say, that there has been more Engines built to this specification then all of the original engines from the factory. It's just that popular and that good of an Engine! Combine that popularity with the ever constant decline of available Engines and parts, and you have a classic. This will be the one that we all look back on and say "Boy what a Engine".

     We specialize in this 03-04 Cobra Engine. We wanted everyone to know that you can get a new Cobra 03-04 Super-charged Engine, or just the parts to build your own Engine, right here from ProWeld. The Engines we offer are 100% new, Ford Cobra Engines! Not some make shift, used want a bee. We build them per Ford Cobra Specifications, with 100% new Ford Parts! ! ! We also can supply you with any replacement parts for you project or all the parts needed to turn your long block into a Cobra replica. Like anything good, it comes in a limited number, and so these parts are getting harder and harder to find, both new and used. We keep a constant look out and supply of both new and used parts. Very soon, the day will come when there will be no more "Terminator" parts from Ford, it's already getting tough…Don't wait any longer for your dream Engine.

 

Ford Racing FR500 4-Valve "Cammer "                                                        Engine

 

     Wow, what a Engine!!  This design competed in many racing organization both here and abroad.  I have always personally wanted one of these Engines, and I finally got my chance and jumped on it.  A true Road Racing Engine, and now I have one of my own…though it needed a little work to make run again.

     This Engine had the most aggressive heads very designed.  The ports were raised to allow a more straight shot from the intake into the Engine combustion chamber, and the intake manifolds were a work of mechanical art.  I have owned every Modular engine made by Ford except for two, the 2000 Ford 5.4L Cobra "R" and this one, the 5.0L Cammer Engine.  Now I have only one Engine left to acquire….some day.   Let me tell you what I learned about the Cammer Engine.

     First there was several 5.0L Cammer Engines produced by Ford.  All were non-production and only available from Ford Racing thru special programs or factory crate Engine options.  The FR500C was a racing Engine used in many classes of racing, and is what I have longed for, for many years.  This engine was produced for Ford by Rousch/Yates Racing Engines, and only available to those that were participating in the Ford Racing events.  The differences are many so let's start with the largest part, the block.  This Engine uses a aluminum block that differs from the production blocks by a fair amount.  The block is cast of better materials and produced in a more controlled environment.  The main journal webbing is much thicker for more reliability and the main bearing caps are of billet steel, with a combination of 4-main studs and 2-side bolts.  The crankshaft is the forged, fully counter-weighted, 8-bolt unit most are frumilure with.  But this one has been knife-edged and the counter weights have been turned down to reduce rotating weight.  Also, the throws have been drilled and the engine rotating assembly balanced.  You have to remember, this was a competition engine, one that will see more HP and many more RPM's then your typical 4-valve Modular Engine, plus the Road Racing aspect will subject this Engine to much more abuse then others would ever see.  So it makes sense to start with a more beefy foundation and to take the time needed to produce excellent results.   Speaking of which, Rousch/Yates is a first class organization.  They build many Engines every year for some of the most respected, and feared racing organizations in the business.  From world class Road Racing teams to NASCAR organization like Rousch, Penske and the Wood Brothers to name a few.  The first thing that strikes you is the time, organization and methods used to assemble these Engines.  The Block itself has been smoothed inside, removing every sharp edge, casting mark and edge.  The parts are scribed with location marks and serial numbers, very professional and accurate.  Internals are dependent on use, but most wear Manley Rods and Male Forged Pistons.  The Bore is 94mm and the heads have larger (31mm) exhaust valves then stock 4-Valve Heads.  Ports are larger, smoother and straighter then other heads, and the Hydraulic lash adjusters on the intake ports have been re-sized.  These smaller lash adjuster, allows them to raise the intake ports for a more direct shot into the combustion chamber, which improves flow and efficiency. 

   The heads themselves also have much different cam bearing caps.  Here they use individual caps, where the typical 4-Valve set-up is to have a cap that secures 3-cam journals at a time.  This provides more support and makes journal service and repair a much simpler and faster job.  Also, oil drain back passages have much larger openings and are cast larger in the block, which promotes better oil control.   Speaking of which, the best windage tray, main bearing cap support, oil control panel you will ever see is included in this engine.  It’s a wonderful piece made by McLaren (yes that same  McLaren that builds and races Formula 1 cars) that holds extremely tight to the crankshaft and has both fins and plates to direct oil and strengthen the bottom end.  That along with a special Oil Pick-up Tube and custom 12-Qt Oil Pan rounds out the bottom end of this amazing Engine.

    The most noticeable and maybe remarkable section is the Intake Manifold and it duct work.  The Intake uses a short ram lower manifold together with a 3-piece cast upper plenum, that directs the incoming air into individual air inlets or horns.  It's a work of art in itself, and takes many of its styling que's from the Cobra R manifold's design.  The biggest change from conventional 4-valve design, is the location of the fuel injectors.  Here they are located up on top of the manifold and inject directly into the center of it, as opposed to being down closer to the port by the head.  Everything has been enhanced to provide the high RPM power band needed in a competition engine package.

   Other differences are in the Valve Covers, with a slight change in location of breather outlet and baffling, more aggressive cams with better springs and retainers.  Also all valve guides and valve seats are bronze not powdered metal.  Also, a very interesting change was made in the front cover.  The timing chain tensioner pivoting guides have not only larger pins to swivel on, but are mounted in a double sheer support method with a support welded to the inside of the timing cover that supports the pivot pin.  This adds considerable strength to that timing chain guide, which gets much abuse due to the higher RPM and constant shifting.   Large Diameter, free flowing stainless steel headers take care of the exhaust gases, which are many at full song.  Up front a small alternator is mounted in the center, and all accessories have been under-driven, again a reflection of the high RPM nature of the Engine.  There is no one thing that makes this a great Engine, it's more a collection of little improvements that make the difference and make this the most impressive 4-Valve Engine for me.  I would consider this block to be the best, most ridged Modular Block available.  And is in fact, used in most every record setting, super high HP, Modular Race Engine out there.  If you ever have a chance to pick-up one of these amazing Engines, don't let it pass you by. 


4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG
4ValveEngines/081214Pictures088.JPG

4ValveEngines/LargeGroupPictureAlbum127421.jpg
New 4.6L Cobra Engine getting wired with new Harness

4ValveEngines/LargeGroupPictureAlbum127421.jpg
DOHC Engine with BBK Headers

4ValveEngines/LargeGroupPictureAlbum127421.jpg
New 04 Cobra with 3-stage N2O & Water Injection

4ValveEngines/LargeGroupPictureAlbum127421.jpg
Ford Flathead Engine with Twin Turbo Set-up

4V American Iron Series Engine

 

Factory Five Kit Car Customer

 

Cobra AC 4-V, 5.4L Engine

 

Click Here

01 Cobra 4V, 4.6L W/Pro Charger

   

98 Cobra 4-V, 4.6L W/"C" Head Conversion

   

01 Cobra 4-V, 5.0L W/Turbo

   

06 FR500C 4-V, 5.0L "Cammer Race Engine"

   

4ValveEngines/LargeGroupPictureAlbum127421.jpg
DOHC Valve Cover

4ValveEngines/LargeGroupPictureAlbum127421.jpg
Original Factory 03-04 Cobra Engine

4ValveEngines/LargeGroupPictureAlbum127421.jpg
4.6l 03-04 Cobra Engine, Polished Blower, BBK Inlet

Pro Weld

5937 Ethan Drive

Burlington, KY 41005

859-586-4069

Proweld@myway.com